Pile fabric



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I II gigga 2 5x52 r u I! 'w aww'; 50 51 f6 45 58 446 47 gr Jul/612E119 54 .76 f6 0 I an n 1 (9/ I til Patented Nov. 9, 1937 PILE FABRIC Walter A. Rice and Frank G. Shinn, Yonkers, N. Y.

A Application March 26,

19 Claims.

Our invention relates to knotted fabrics with knots of V the general character of Persian or Sehna rugs, but which contain warp threads of two distinct types, (1) those corresponding in general with normal chain warp threads in that they have normal warp thread tension and are woven in with the weft threads but also carry tufts, called herein chain warps, and (2) other warp threads comparable with stuffer or filler warp threads in their character and in the extra tension put upon them by entering into the weave to the extent that knots are-formed about some of them. These of the second type improve the body, assist in retaining accurate width throughout and reduce tendency to pucker'and are called herein stufier type or filler type warps.

A purpose of our invention .is to introduce stuffer warps in a tufted or knotted fabric parallel with the chain warps in such manner as to reduce tendency to pucker in the finishedfabric, and'to cover the stuifer type warps at the back by the tufts or knots.

A further purpose is to introduce weft threads in combination with'stuffer warps in a tufted or knotted fabric having the tufts or knots surrounding the warps so as to prevent narrowing of the fabric during weaving.

In a fabric containing stuifer or filler type warps a further purpose is to produce a Persian or Sehna knot weave having all of the yarn tufts in one course formed as right hand knots, and all of the yarn tufts in the next course formed as left hand knots, adjoining courses alternating right and left hand throughout the weave.

In a fabric containing stuffer or filler warps, a furtherpurpose is to produce a Persian or Sehna lmot weave having the yarn tufts in adjoining courses formed about pairs or sets of warps which differ in the pairing or arrangement of the warps.

In a fabric containing stuffer type or filler type warps, a further purpose is to produce a Persian or Sehna knot weave having the yarn tufts in adjoining courses formed about pairs or sets of warps which diifer in the pairing or arrangement of the warps, and the knots alternating, right and left hand in adjoining courses.

A'further purpose is to bind Persian or Sehna knots upon chain and stuffer type or filler type warps arranged in trios of two chain warps and one stuffer type warp, the stuffer type warp having any given position or relation with respect to the chain warps, and using wefts of a single shot of yarn.

A further purpose is to bind Persian or Sehna knots upon chain and stuffer type or filler type 1932, Serial No. 601,420

warps intoa tufted fabric and at the same time cover up the stufier type warps so that they shall not show objectionably through from the back of the fabric.

A further purpose is to cover stuffer type warp threads in a fabric by pile yarn so that the stuifer type warp threads will not show sufficiently at the back of the fabric to interfere with the symmetry of the design;

A further purpose is to provide various alternative available combinations of stuffer type and chain warp threads and knots in a tufted fabric.

A further purpose is to form combinations of different or differently placed tuft knots without interfering with the advantages secured from stuffer type warp thread use.

A further purpose is to include stuffer warp threads along with chain warp threads within the knots or loops of a pile fabric covering the stuffer warp threads within the knots by the pile yarn.

Further purposes will appear in the specification and in the claims.

Our invention comprehends not only the methods or processes involved, but fabrics produced by the methods or processes.

Without the least attempt to show all of the forms in which our invention may appear, we present aconsiderable number of illustrative constructions for the purpose of showing the breadth of the invention and its applicability to condi tions variant not only in the number of chain and filler type warp'threads to the same cycle, but in the position of the filler warp threads with respect to the chain warp threads, in the position of the knots, the number of warp threads included within each knot, in the grouping of the warp threads for a knot engagement, whether the same be in successive rows or different in successive rows, and the placing of the knots whether right-facing or left-facing in the rows of a1- ternating in adjoining rows.

We have also shown variant wefts in some of the different structures to indicate the novelty of some of the combinations shown.

Figure 1 is a perspective elevation of the face of one form of our improved fabric, showing the warp threads, wefts and tuft loops, all separated or extended as though loosely woven, and their size magnified.

Figure 2 is a sectional elevation of the fabric shown in Figure parallel with the lengths of the warp threads.

Figures 3, 5, '7, 32, 34, 36 and 38 are views graphically similar to Figure 1 but showing variations of knot formation or location. 7

Figures 4, 6, 8, 33, 35, 37 and 39 are sectional elevations of Figures 3, 5, 7, 32, 34, 36 and 38 respectively, taken parallel with the lengths of the warp threads. I

Figure 8a is a slight modification of Figure 8.

Figures 9 to 26 are enlarged sectionsof knot formations, not intended to be a complete showing of the possible knots but sufficiently complete to illustrate that Wide variation is available in the arrangement of warps and formations of knots. Some of the knots are formed right hand and some left hand.

Figures 27a, 27b, 270 in one group; 28a, 28b, 280 in a second group; 29a, 29b, 290 in a third group; 30a, 30b, 300 in a fourth group and 31a, 31b, 310 in a fifth group are arrangements in each group of a plurality of enlarged sections of knot formations with the immediate weft shown in position and illustrating in each group successive arrangements of adjoining courses.

In Figures 40 and 41 warp threads only are shown to illustrate the fact that in four-warpthread combinations the stuifer type warp threads can represent the outside threads of the group of 4 or the inside threads of a group of four according to the judgment of the designer in View of the information here given.

Throughout the drawings the stuifer type warps are illustrated in shaded lines, while the chain warps are shown by double lines, as are the wefts and tufts.

In the drawings similar numerals indicate like parts.

In the manufacture of knotted rugs it is quite desirable to use stuifer type or filler type warp threads in order to maintain the width and increase the stiffness or body of the rugs. The insertion of stuffer type or filler type warp threads has been objectionable in the past for the reason, among others, that these warps have not been covered sufficiently at the back and that the stuffer type or filler type warp threads have not been fully coordinated with the rest of the rug. The failure to cover suificiently causes interference with the symmetry of the design. We offer relief from this partially or completely by surrounding the filler type warp threads by some or by all of the knots by which the tufts are made. We very thoroughly bind the stuifer type warp threads into the rug by passing the material of the same knots about the stuifer type warp threads and the chain warp threads so that the filler type warp threads are tied to the rug not only by the normal weaving operation, but by the knots as well.

In the figures the warp threads are arranged in various repeated groups preferably three or four to the group, each group containing at least one stuffer type or filler type warp thread and two chain warp threads.

Within the groups there are as illustrated either two chain warp threads to one stuffer type warp thread or chain warp threads alternating successively or in pairs with stuffer type warp threads.

For convenience in reference we have given all of the warp threads shown individual reference characters notwithstanding that they repeat successively in groups of three or of four only. In the four-warp-thread group such as in Figures 34-41, the stuffer type warp threads are shown two to each group, at 45, 46, 41, 48, 49, e, 5| and 52. In the three-warp-thread groups, such as Figures 1-8 the stufier warp threads are shown one to each group at 45, 41, 49, 5| and 53. The chain warp threads are shown in the three-warpthread groups at 54453 and in the four-warpthread groups at 54, 55, 58, 6D, 62, 64, 66 and 68.

The knots shown are as of eight types or arrangements differing in being rights or lefts, containing one warp thread only within the eye or two warp threads within the eye and/or looping one or two warp threads. Different locations of the stuffer type and chain warp threads within or with respect to the eyes and loops also affect the situation.

The knots are shown separately with the eye enclosing one warp thread only and the loop enclosing one warp thread only, right at (39, Figures 11, 15, 16 and 23 and left at 70, Figures 12, 19, 20 and 26; with the eye enclosing one warp thread only and the loop enclosing two warp threads, right at H in Figures 9, 14, 22 and left at 12 in Figures 18 and 25; with the eye enclosing two warp threads and the loop enclosing one warp thread, right at E3 in Figures 10, 13 and 21 and left at 14, in Figures 17 and 24.

In Figures 32 to 39 knots are shown enclosing two warp threads in the eye and also two warp threads in the loop, right at 15 and left at I5.

It is recognized that these are all Persian or Sehna knots of recognized type and that the question of right or left formation and of the number of warp threads enclosed within the eye and loop parts of the knot, respectively, will depend upon the location intended for the tuft ends, the proportion and placing of the stuffer type warp inserted and other factors.

It will be apparent that with all of these formations shown, the knots enclosing a total of two warp threads only may be made to enclose (back, that is, cover the back of) a stufier type warp thread or not as desired; that with a threewarp grouping the knots which enclose three warp threads will always back the stuffer type warps; that with a four-warp formation a knot enclosing three stuffer type warp threads may be made to enclose and back both stuffer type Warp threads or one only as preferred; and that with a four-warp thread grouping a knot enclosing four warp threads will necessarily enclose and therefore back and cover all of the warp threads.

With all of the knots indicated as seen above there can be wide variation as to which one or which ones of the warp threads is or are made stuffer type warp threads and which one or ones is or are made chain warp threads. We have gone into this description to the extent above for the purpose of showing the wide flexibility of our invention in applying to all kinds of combinations of chain and stnifer type warp threads in differing relations with combinations of size, proportion of eye to loop, right and left presentation and lateral shifting location of the knots used while still carrying out the coverage feature of our invention either completely to form 7 weft threads 11 and 18 are shown between adjoining rows of tufts the weft threads being separately applied and alternating one over and the other under the same. warp threads. 7

In Figures 3 and 4 groups of three warp threads are shown with the same weft provision as in Figures ,1 and 2. However, the knots are of the 13 type, having each eye of a knot encircling a stufier type warp thread and a chain warp thread and the loop enclosing the second chain warp thread of the set. The knotsare all right handed here.

In Figures 5 and 6 right and left hand knots 59 and I areshown, the eyes of successive rows of knots encircling the same chain warp threads Y and the loops of the knots surrounding the adjoining warp threads on opposite sides respectively so that one row of knots covers the backs of the stuffer type warp threads and the other row of knots does not. This gives partial coverage. The weft thread arrangement is the same as in Figures 1 to 4.

In Figures 7 and 8, also a three warp thread grouping having the same character of Weft as in Figures 1 to 6, the same character of knot 69 is used for all of the rows as for the right hand knot rows in Figure 5, but the eye of each knot encircles the stufier type warp thread of this group so that one chain warpthread of each group is not covered. This formation gives knot coverage for all of the stuifer type Warp threads except, of course, in the distance between the loops where the two wefts lie in which half of the weft threads lie over and half under the stuffer type warp.

Figure 8a is intended to indicate four weft threads ll, l8, l9 and 80 for each row of tufts or knots, the four weft threads alternating above and below the stuffer type warp threads and between them and the chain warp threads.

In Figure 27 groupings of three are shown with knots H and 12 whose eyes each encircle a chain warp thread and whose loops each enclose one stuffer type warp thread and one chain warp thread. This is true notwithstanding that successive rows are rights and lefts respectively so that the chain warp thread enclosed by the eye is difierentin successive rows or courses.

Any suitable shuttleor needle-laid weft may be used.

In Figure 28 the knots 24 are all left hand and the successive rows surround different group- I ings of three warp threads so that the stuffer type warp thread forms the middle of the group in one row and is surrounded by the eye of the knot, but forms an end of its group in the next row and is surrounded by the loop of the knot, Here, as in Figure 27, there is full knot coverage for all of the stuffer type warp threads.

In Figure 29 the knots H and 12 arerights and lefts respectively and there is a shift in the grouping of the warp threads in successive rows. By reason of the location of the stuffer cluded within the eyes of the knots in all of the rows but would form full knot coverage in any event.

I 'In Figure 33 right and left knots 69 and H! are used, each covering a pair of warp threads but shifting the pair, within-a three warp thread arrangement in successive'rows, with the result 7 that in alternate rows the stuffer type warp threads are not enclosed within the knots and there is only partial knot coverage for the stuffer type warp threads. This is true also of Figure 31 where all of the knots are right hand knots 69 but where the pairs covered by the knots are-shifted in alternate rows. 7

In Figures 32 to 41 all of the groups are fourwarp-thread groups and each of the knots encloses two warpthreads within each eye and two warp threads within each loop.

- The arrangements of the warp threads are the same in Figures 32 to 39, alternating stuifer type warp threads and chain warp threads but in Figures 40 and 41 the stuffer type warp threads are both on the outside of the group in Figure 40 and both on the inside of the group in Figure. 41. This means that across the rug two stuffer type warp threads will adjoin each other and two chain warp threads will'adjoin, alternating inpairs but differently divided in the grouping for tuft application.

In Figures 32 and 33 the knots are in line along the length of the rug with the same warp thread grouping for application of the knots.

In Figures 34 and 35 the warp thread grouping is the. same but the knots of successive rows or courses are right and left respectively.

In Figures 36 and 37 the knots are all right hand knots and the pairing differs in alternate courses of knots, the eyes of the knots surrounding. different pairs in one course from the pairs surrounded by the eyes in the next course. In Figures 40 and 41 the warp threads are paired the same-for successive courses, but the knots are alternated, rights in one course and lefts in the next.

In Figures 32 and 33 the weft threads alternate, one weft over and one weft under the same warp threads, treating the warp threads in pairs, 1. e., one over one pair of adjoining warp threads and the other under the same pair of warp threads between each two courses.

In Figures 34 and 35 the weft threads alternate but alternate 'in position with the chain warp threads and with pairs of stuifer type warp threads. One goes over a chain warp thread and under the next three warp threads and the other reverses these positions.

In Figures 36 and 37, 38 and 39, the two weft threads are carried through together both over the same warp threads and both under the same warp threads, the warp threads alternating-in pairs.

' In Figures 40 and 41 any of the knot formations indicated can be used along with any weft formation, the figures being shown to indicate only a different arrangement of the stufier type Warp threads and chain warp threads respectively.

Where two weft threads only are used between two adjoining rows of tufts or knots as in Figures 1 to 8' there are advantages in both forms shown in Figures 1 and 3 and in Figures and 7, respectively. In the earlier of these forms the positions of the warp threads in the sheds are changed so that the weft threads 11 pass over the warp threads under which the Weft threads 18 have passed and pass under the warp threads over which the weft threads 18 have passed. This requires shuttle operation. If a needle were used each fshot would lay two weft threads for each shed position. 1

In the form of Figures 5 and 7 the two weft threads 11 and 18 are carried both under the same warp threads and both over the same other warp threads. This is wellsuited to needle insertion.

With nearly the same tuft or knot spacing, the forms of Figures 1 and 3 gives a firmer fabric whereas the forms of Figures 5 and 7 gives a looser fabric, which, when made in a loom, is more nearly comparable with hand work than the other.

The tuft or knot spacing will be a trifle close with the second forms because of the additional shedding operation in the first form and the corresponding more compact beating up in the second form.

The conditions discussed in regard to Figures 1 and 3 as compared with Figures 5 and 7 in a three-warp-thread grouping are also present in Figures 32 and 34 as compared with Figures 36 and 38 in a four-warp-thread grouping.

In view of our invention and disclosure variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art, to obtain all or part of the benefits of our invention without copying the structure shown, and we, therefore, claim all such in so far as they fall within the reasonable spirit and scope of our invention.

Having thus described our invention, what We claim as new and desire to secure by Letters Patent is:

1. A knotted pile fabric having stuffer type warp threads woven straight through the fabric in unbending relation and chain warp threads which are bent below andabove the weft, weft uniting the stuffer and chain Warp threads and tuft knots passing back of all of the warp threads and forming a back for them.

2. A knotted pile fabric having stuffer type warp threads which are woven straight through the fabric in unbending relation and chain warp threads bent above and below the warp threads, in groupings of one stuifer type warp thread to two chain warp threads, weft uniting the warp threads and Persian knots having their eyes about chain warp threads only and their loops about stuffer type and chain warp threads.

3. A knotted pile fabric having stuffer type warp threads woven straight through the fabric in unbending relation and chain warp threads which are bent below and above the weft, in groupings of three, one stuffer type Warp thread to two chain warp threads, weft uniting the warp threads and Persian knots having their eyes each about one of the warp threads and their loops about one each of the warp threads and including a stuffer type warp thread within each knot.

4. A knotted pile fabric having stufier type warp threads woven straight through the fabric in unbending relation and chain warp threads which are bent below and above the Weft, in groupings of three, one stuffertype warp thread to two chain Warp threads, weft holding the warp threads together and Persian knots having their eyes each aboutone of the warp threads and their loops about the othertwo of the warp threads, and covering the stuffer type warp threads atthe back.

5. A knotted pile fabric having stuffer type warp threads woven straight through the fabric in unbending relation and chain warp threads which are bent below and above the weft, in groupings of three, one stuffer type warp thread to two chain warp threads, weft holding the warp threads together and Persian knots about the warp threads having their eyes each about two warp threads of the group and their loops each about the third of the warp threads, and forming a backing for the stufier type warp threads.

6. A knotted pile fabric having stuffer type warp threads woven straight through the fabric in unbending relation and chain warp threads which are bent below and above the weft, in groupings of three, one stuffer type warp thread to two chain warp threads, weft holding the warp threads together and Persian knots about the warp threads including in each knot a stuffer type warp thread and having right-handed knots in one course and left-handed knots in the next course of knots.

'7. A knotted pile fabric having stuffer type warp threads woven straight through the fabric in unbending relation and chain warp threads which are bent below and above the weft, in groupings of three, one stuffer type warp threat to two chain warp threads, weft holding the warp threads together and Persian knots about the warp threads having right-handed knots in alter nate courses and leit-handed knots in intermediate courses and having different groupings of the warp threads within the knots in adjoining courses, but each knot including a stufier type warp thread.

8. A knotted pile fabric having stuifer type warp threads woven straight through the fabric in unbending relation and chain warp threads, which are bent below and above the weft, in groupings of three, one stuffer type warp thread to two chain warp threads, weft holding the warp threads together and Persian knots about the warp threads having different groupings of the warp threads within the knots for adjoining courses of the knots, but each knot including a stuffer type warp thread.

, 9. A knotted pile fabric having stuffer type warp threads woven straight through the fabric in unbending relation and chain warp threads, which are bent below and above the weft, we holding the warp threads together and Pei i knots, each knot about stuffer type and chain warp threads having alternating right and left knots differently placed with respect to the grouping of the warp threads in adjoining courses.

10. A knotted pile fabric having stuffer type warp threads woven straight through the fabric in unbending relation and chain warp threads which are bent below and above the weft, in groupings of one stufier type warp thread to two chain warp threads, weft holding the warp threads together and Persian knots about the warp threads having the eyes and loops, respectively, of each knot, one including two warp threads and the other one warp thread of a group including a stuffer type warp thread in each knot.

11. A knotted pile fabric having stuffer type warp threads woven straight through the fabric in unbending relation and chainwarp threads which are bent below and above the weft, in groupings of one stuffer type warp thread to two chain warp threads, weft holding the warp threads together and Persian knots about the warp threads having the eyes and loops of the knots including for each knot one two-warp threads and the other one-warp thread of the group and differing in the grouping of the warp threads in adjoining courses of knots;

12. A knotted pile fabric having stuffer type warp threads woven straight through the fabric in unbending relation and chain warp threads which are bent below and above the weft, arranged in groups successively recurring across the fabric, weft holding the Warp threads together and knots about the warp threads difiering in the lumber 'of warp threads included in the knot from the number of warp threads included in the group but each knot including a stuffer type warp thread, the knots forming backing' for all of the stuffer type warp threads across a weftwise course of the fabric.

13. In a knotted pile fabric having stuffer type warp threads woven straight through the fabric in unbending relation and chain warp threads which are bent below and above the weft, a three-warp thread grouping, knots including two warp threads, one of which is a stuffer type warp thread and weft thread between the courses of the fabric. a

14. A knotted pile fabric having stufier type warp threads woven straight through the fabric in unbending relation and chain warp threads which are bent below and above the weft, weft holding the warp threads together and Persian knots having the eyes of the knots surrounding and forming a back coverage for their respective stuffer type warp threads and the loops engaged each with a chain warp thread.

15. A knotted pile fabric having stufier type warp threads woven straight through the fabric in unbending relation and chain warp threads winch are bent below and above the weft, weft holding the warp threads together and Persian knots characterized by the loop of each knot forming coverage for the back of a stuifer type warp a thread and the eye of each knot surrounding a chain warp thread.

16. In a pile fabric, stuffer type warp threads ,Wovenstraight through the fabric in unbending relation and chain warp threads which are bent below and above the weft, arranged in groups of two chain warp threads to one stuifer type warp thread, rows or courses of Persian knots about warp threads only, including each a stuffer type warp thread and each forming backing for the stuffer type warp thread and for a chain warp thread and weft threads between the courses of knots comprising two weft shots between each two courses of knots, one weft shot under certain warp threads over which the other weft shot passes and over certain warp threads under which the other weft shot passes.

17. A knotted pile fabric having warp threads in groupings including each two classes, one a stuffer type warp thread woven straight through in unbending relation and the other two chain warp threads which are bent below and above the weft, Weft holding the warp threads together and Persian knots about these warp threads having the eyes of the knots each about warp threads of one class and having their loops each about warp threads of the other class.

18. A knotted pile fabric having stuifer type Warp threads woven straight through the fabric in unbending relation and chain warp threads which are bent below and above the weft, side by side throughout the width of the fabric, weft holding the warpthreads together and knots about both stuifer type and chain warp threads including and forming backing for the stuffer type warp threads.

19. A knotted pile fabric having stuffer type warp threads woven straight through the fabric in unbending relation and chain warp threads which are bent below and above the weft, in groupings of three warp threads, weft threads binding the warp threads together and having the knots of the fabric each passing about one stufier type warp thread and at least one chain warp thread and forming a cover for the back of the stuffer type warp thread of its group.

WALTER A. RICE. FRANK G. SHINN. 

